Revision 1. March 21, ADC Operation Manual N 11 th St San Jose CA

Transcription

1 Revision 1 March 21, 2017 ADC Operation Manual N 11 th St San Jose CA

2 Index 1. Installation Required PC specification Software 3 2. Operation Connection Menu System Settings 6 1) Fastening 6 2) I/O 7 3) Screw count 11 4) Advanced function 12 5) Controller 1 & ) Multi sequence 14 7) Model setting Monitoring 19 1) Real-time monitoring 19 2) Graph monitoring 20 3) Remote control & I/O status monitoring 20 4) Process capability monitoring 21 5) Auto Customizing 22 6) Error history 24 7) Synchronizing fastening by torque Error & system alarm code System error Fastening error System alarm N 11 th St San Jose CA

3 1. Software installation 1.1 Required PC specification - OS : Windows 7 or later version 1.2 Software - Software file : ParaMon v0.00 yyyymmdd.zip - Install file : setup.exe The higher version of software will overwrite the lower version of ParaMon software. 2. Operation 2.1 Connection ParaMon pc software have 4 selectable connecting options to the MDC or ADC controller. MDC controller : Serial RS232C or Ethernet ADC drive : Serial RS422 or USB Serial COM port connection requires the information about COM port, Baud rate and the device ID SERIAL (MD) Ethernet (MD) USB (AD) SERIAL (AD) 2.2 Menu There are 3 main menu. - System - Settings - Monitoring N 11 th St San Jose CA

4 System Manufacture only Firmware Downloader Language Settings Fastening Preset #1-15 (torque, speed, angle, soft start, etc) Input / Output I/O port definition Screw count Number of screw, cycle start, complete signal Advanced F Controller 1 Free reverse, screw engaging detection, fastening sequence and angle after torque-up Time limit of run, motor stall, display, complete signal. And other settings of controller. Controller 2 Screwdriver operation, error pattern, Serial communication, torque unit, screw type Multi sequence 10 steps of multi sequence programing for 1 cycle Model setting 10 steps of sequence programing by managing preset#, input and output signals. Monitoring Real-time(data) Fastening data output on any event (Real-time) Graph 2 channel fastening data curve Remote control Start, F/R remote control with I/O monitoring Process capability STDV, CP and CPK with real-time CP curve Error history Latest 8 error history Be sure that the changed parameter on the ParaMon pc software is reflected to the ADC drive immediately N 11 th St San Jose CA

5 2.2.1 System 1) Firmware downloader Drive firmware can be replaced by the below process. Use USB port only. for firmware download. Ethernet is not allowed ) Disconnect USB connection of ParaMon from the Drive. 2) Click Firmware Downloader 3) Click Load on the pop-up window, and select the firmware file on the pc. 4) Click Start 5) See the message Firmware upload complete in the message window, and click Close to finish the process. 6) Turn the power of the controller OFF, and ON again to initialize the settings N 11 th St San Jose CA

6 2.2.2 Settings 1) Fastening Double click to open parameter There are 15 preset groups for fastening setting. Each preset # consists of torque, speed, Min & Max angle for fastening OK range, soft start, Free speed before tightening. - Control type : TC/AM or AC/TM ( torque control angle monitoring or angle control torque monitoring ) - Torque : Target torque - Torque limit (%) : OK torque range in AC/TM mode - Target angle : Target angle in AC/TM mode - Min angle (degree) : Minimum angle to be OK in TC/AM mode - Max angle (degree) : Maximum angle to be OK in TC/AM mode - Snug torque(%) : Point (% from target torque) to start monitoring angle in TC/AM mode - Speed : Target speed. Speed is changed by torque setting automatically. To change manually, Auto Speed N 11 th St San Jose CA

7 must be Disabled in Control 2 - Free speed : Manual setting speed. Shift back to the auto speed after the free angle running - Free angle : Angle for Free speed. - Soft start(ms) : Speed reach to the target in the setting time - Seating point(%) : Auto speed slow down to ramp-up speed for torque control - Torque rising time(ms) : Time setting from seating point to the target - Torque holding time(ms) : Target torque holding time - Torque compensation(%) : Preset # has each torque compensation value. 2) Input / Output management The digital I/O provide the free assignment feature for Input and Output. Factory setting of I/O assignments are as following. To validate changing I/O, turn the power OFF and ON again N 11 th St San Jose CA

8 Digital I/O mapping factory setting Description Digital Input Description Digital Output Preset select 1 Input 1 Torque up Output 1 Preset select 2 Input 2 Fastening OK Output 2 Preset select 3 Input 3 Ready Output 3 Start Input 4 Motor Run Output 4 Fasten / Loosen Input 5 Alarm Output 5 Lock Input 6 Status For/Rev Output 6 Multi sequence Input 7 Count Complete Output 7 Reset Input 8 Alarm 1 Output 8 Count Start - Alarm 2 Count Reset - Alarm 3 Count Out - Sync Out Preset select 4 - Model Complete Sync In - Sync resume - CW Lock - CCW Lock - Model Cancel N 11 th St San Jose CA

9 ADC 50P I/O details 50P I/O pin no. Description Factory setting 11, 21 IN COM 12 IN 1 Preset select 1 13 IN 2 Preset select 2 14 IN 3 Preset select 3 15 IN 4 Start 16 IN 5 Forward / Reverse 17 IN 6 Driver Lock 18 IN 7 Multi sequence 19 IN 8 Reset 22 IN 9-23 IN IN IN IN IN IN IN OUT 1 (+) Torque UP 36 OUT 1 (-) 37 OUT 2 (+) Fastening OK 38 OUT 2 (-) 39 OUT 3 (+) Ready 40 OUT 3 (-) 41 OUT 4 (+) Motor RUN 42 OUT 4 (-) 43 OUT 5 (+) Alarm 44 OUT 5 (-) 45 OUT 6 (+) Status F/L 46 OUT 6 (-) 47 OUT 7 (+) Count complete 48 OUT 7 (-) 49 OUT 8 (+) 50 OUT 8 (-) Connector model : 3M MDR A2PL N 11 th St San Jose CA

10 Binary coding with 5 inputs to select preset # Input Preset # Preset select 4 Preset select 3 Preset select 2 Preset select 1 Multi sequence Multi A Multi B Binary coding with 3 outputs for error codes in 7 groups Error code Alarm 3 Alarm 2 Alarm 1 110,113,114,115,116,118,200,201, ,301,302,303,304, , , , ,334,335, AL-xx Alarm (System alarm) N 11 th St San Jose CA

11 3) Screw count Total count number Middle count number Count start signal In Count complete signal Out Count complete signal Out Count start signal (IN) 1) No signal, auto start (Auto) - auto reset to total number after 0 2) Sensor or switch with one trigger pulse - Count starts with only trigger pulse. Counting is valid until complete or reset. Reset calls count NG 3) One trigger pulse with timer for counting - Counting should be completed within the time of timer from the trigger pulse, otherwise count NG 4) One trigger pulse to start counting, another trigger pulse to stop counting and evaluate OK or NG. Any remaining number calls count NG Count complete signal (OUT) If mid count number is used, count complete signal out is provided on mid count number and reset on the cycle completed N 11 th St San Jose CA

12 4) Advanced functions There are 4 steps of Advanced Function to customize the screw fastening process. Step 1 (Option) : Free Reverse rotation to guide the screw into the screw hole smoothly with low speed N 11 th St San Jose CA

13 Step 2 (Option) : Engaging torque detection The monitoring angle count is reset and start again from the engaging torque detection point which the screw start joining the thread. It is possible only when the screw engaging provide significantly higher torque than previous free run. Engaging torque setting is by percentage of target torque. Step 3 (Preset) : Free Speed The system auto speed by torque setting can be manually replaced to have higher or lower speed than it s original auto speed during the limited angle setting. Be sure that the free speed run should stop before the screw seating point which screw start to tightening joint. To use this option, go the Fastening setting menu. Step 4 (Preset) : Fastening sequence have the important parameter factors to the tightening quality. 1) Seating point (%) : It is trash hold point at that the target speed is shifting to torque up process. The factory setting is guided from hard joint. If the it is soft joint, the setting can be higher percentage of the target torque. 2) Torque rising time(ms) : It is the speed and time during ramp-up to the target torque. Quick or slow speed to the target torque according to the condition. 3) Torque holding time(ms) : Tool holds the target torque for the time setting. It stabilizes the tightening condition. Step 5 (Option) : Angle after torque-up(a261) : It manage extra angle control in both forward or reverse direction after tightening by torque. 5) Controller 1 & N 11 th St San Jose CA

14 Forward / Reverse motor RUN time, and motor stall time is limited for motor safety. The following parameters is ideally recommended to be kept with factory setting in all application. - Forward RUN time limit (A270) : Run limit to forward rotation - Reverse RUN time limit (A271) : Run limit to reverse rotation - Motor Stall time limit (A272) - Acceleration (A274) : Slow start of motor to the target speed - Auto speed (A290) : ENABLE provide the safe speed on the torque setting - Driver model no.(a281) : not changeable. Auto recognized Other parameters are selectable and changeable for application requirements. - Torque unit (A301) : Kgf.cm / Kgf.m / cnm / Nm / ozf.in / lbf.in / lbf.ft Whenever the unit is changed, the controller should be reboot again - Fastening stop error (A293) : DISABLE does not creat any NG when the tool stop without torque up fully tightening. 6) Multi sequence N 11 th St San Jose CA

15 Command details Command Description NOP No operation Fastening tool start fastening process in forward rotation Loosening tool start loosening process in reverse rotation Select preset# Select preset # Delay time delay for setting time Jump Move to the setting step Count value = A Total number A to count Sub if (A) End Subtract 1 from A and save the value replacing A. If the value A is not 0, then move to the next lower step. If the value A is 0, then move to 2 nd lower step Finish multi-sequence process Multi sequence provide a cycle of fastening by a start signal. Total 10 steps of programing is allowed in MA(Multi A) and MB(Multi B) presets To program, select the command and required parameter on each step. To finish the multi sequence programing, last step command should be END [ Example of Multi sequence step program ] Setp no Command Parameter Step 1 Count Value = A 10 Step 2 Select Preset# 1 Step 3 Fastening Step 4 Loosening 5 Step 5 Select Preset# 3 Step 6 Fastening Step 7 Sub if (A) Step 8 Jump 2 Step 9 End Step 1 : Total counting number is 10 Step 2 : Preset #1 selected and move to the next step Step 3 : Start fastening and stop by torque or angle setting, and move to the next step Step 4 : Loosen 5 turns and move to the next step Step 5 : Preset #3 selected and move to the next step Step 6 : Start fastening and stop by torque or angle setting, and move to the next step Step 7 : Subtract 1 from 10 and save 9 by replacing 10. If the value A is not 0, then move to the next lower step. If the value A is 0, then move to 2 nd lower step Step 8 : Jump to step no N 11 th St San Jose CA

16 Step no.2 to Step no. 6 works for a cycle. Total 10 cycles are operated automatically by a start signal. Any failure or NG on each step, Multi-sequence process stops and provide the alarm signal. 7) Models It provides sequential screw tightening with screw counting feature together with I/O and time delay managing by programing in 10 steps. There are 4 different type of command Input, Output, Fastening and Time delay Each step can have one of the above four commands with related setting value The fastening with counting number follows all settings and features in Screw Count menu except the number of screw. There are total 15 programable Models. Once Model is selected, the digital inputs for preset # select becomes model # select automatically. To use Model feature, select Enable on the menu of Controller 2 - Model select (A292). The spindle can be locked automatically in all steps except Fastening step, by selecting Enable on the menu of Controller 1 Automatic driver lock (A284) N 11 th St San Jose CA

17 Command details Command Description Data 1 Data 2 Input Mapping digital Input Input # select from : No output à NG 1 : Active High 2 : Active Low 3 : High status 4 : Low status Output Fastening Mapping digital Output Start fastening Output # select from 1-8 Preset # from : No Output à NG 1 : On 2 : Off 3 : On for 0.5s and Off 4 : On for 1.0s and Off Count number from Delay Delay time sec. (unit: 0.1s) [ Example of Model programing ] Step Command Data 1 Data 2 Description Step 1 Input 5 1 Step 2 Fastening 2 3 Step 3 Delay Step 4 Output 2 3 Step 5 Fastening 3 5 Step 6 Output 3 4 If there is input signal turning on in Input no.5, then move to the next step Fastening total 3 screws with preset# 2. If fastening of all screws are completed, then moves to the next step. If there is the cycle start condition except Auto on the menu of Screw Count, counting will start only with the cycle start signal input. And if the workpiece is removed without complete of count number, Model process can be stopped by Model cancel (input). Refer 3) Screw Count on the manual Delay for 0.5 seconds. Then move to the next step Provide 0.5s pulse ON signal output in Output # 2. Then move to the next step. Fastening total 5 screws with preset# 3. Then moves to the next step. Screw counting condition is same as Step 2 Provide 1.0s pulse ON signal output in Output # 2. Then move to the next step N 11 th St San Jose CA

18 Step 1 : Read the sensor signal when it detect the workpiece loading - Connect sensor to Digital Input 5 (pin no.16) - I/O setting à Input 5 : None Step 2 : Screw tightening with Preset #2 Number of screw = 3 Step 4 : Provide output signal for 0.5 seconds - Connect buzzer to Digital Output 2 (pin no. 37 & 38) - I/O setting à Output 2 : None Step 5 : Screw tightening with Preset #3 Number of screw = 5 Step 6 : Provide output signal for 0.5 seconds - Connect buzzer to Digital Output 3 (pin no. 39 & 40) - I/O setting à Output 3 : None N 11 th St San Jose CA

19 2.2.3 Monitoring 1) Real-time monitoring Setting of Auto Data Out (A297) should be Disable for Monitoring The following data are monitored automatically on every event as like motor run, torque up, Forward / Reverse change, preset # change, etc. - Date & time - Fastening time - Preset # - Target torque - Converted torque - Speed - Angle 1 ( angle from motor start to screw seating point ) - Angle 2 ( angle from screw seating point to the end ) - Angle 3 ( Angle 1 + Angle 2 ) - Snug Angle(degree) : angle from snug torque to the end - Error code - Screw count no. - Forward / Reverse status - Status ( OK, NG ) The monitoring data can be saved in CSV file. And it can open the file N 11 th St San Jose CA

20 2) Graph monitoring Total 200 real-time data are displayed with curve together in two channel. - Torque, Speed, Angle(degree), Angle(turn) and current - Data sampling rate : 5ms (1s), 10ms(2s), 15ms(3s) - Data display option : Fastening, Loosening, All The monitoring data can be saved in CSV file. And it can open the file. 3) Remote control & I/O status monitoring The tool is operated remotely for the followings. - Fastening / loosening rotation, - Tool Start - Tool lock & unlock The following main signal status and I/O are monitored and displayed together with torque, speed and current curves. - Ready, Tool start/stop, Torque up, Fastening OK, Alarm, F/R, I/O N 11 th St San Jose CA

21 4) Process capability display From real-time monitoring fastening torque data, the following statistical data are calculated and displayed. The data is updated automatically for every fastening until monitoring cancelled. - Average, Standard deviation, CP, CPK N 11 th St San Jose CA

22 5) Auto customizing AD tool has the auto speed feature against torque setting not to provide any over torque by speed shock. The auto speed is safe speed on the hard joint condition. On the real application, the settings can be changed manually. Auto customizing feature provides most optimized parameter settings for saving cycle time on the real application. Speed Torque time Click Auto Customizing menu to open the menu N 11 th St San Jose CA

23 1 Select Preset # to modify parameter settings 2 Select one of Soft & Hard joint condition when it is obviously clear or both together when it is not clear to be clarified, then click START 3 Apply screw tightening several times until there is no more parameter changing on the simulation & modification window. Be sure that the fastening condition should be same during the process. The system changes parameter values by the previous fastening data. 4 Once there is no more changes on the simulation & modification window, click STOP to finish testing. 5 Click APPLY to apply the settings on the simulation & modification window. The setting can be modified by manually before applying them N 11 th St San Jose CA

24 6) Error history display The latest 8 tool error (system error only) histories which are saved in the controller ATTENTION : communication is disconnected ATTENTION : communication is disconnected ATTENTION : communication is disconnected Log history is information about the communication of PC to the tool N 11 th St San Jose CA

25 7) AD Synchronizing Two or more spindles up to maximum 31 spindles can be operated with a torque synchronized condition. The spindle drives should be linked by I/O to be synchronized. One drive should be Master and the others should be slaves. To monitor the torque curve of the multi spindles on the separate software- AD Synch, each drive should be connected to the PC by RS422 communication port. The torque curve of maximum 4 spindles can be monitored on a screen with different colors together. But total 31 spindles can be operated in synchronized condition N 11 th St San Jose CA

26 [ Setting & Wiring ] Parameter setting 1 A304 Synchronization : Enable 2 A305 Synch Master : The only 1 st spindle should be Master 3 A306 Waiting before sync step (ms) : Torque synchronization process starts from the torque seating point. The time to reach to the seating point. Once all spindle reach to the seating point, then move to the next step together. 4 A307 Waiting to sync step (ms) : There are 10 sync steps up to the target torque. The waiting time limit between sync steps before moving to next step together. AD Sync Monitoring COM port COM port COM port COM port Master Slave Slave Slave I/O I/O I/O I/O Start (in) Run (out) Start (in) Run (out) Start (in) Run (out) Start (in) Run (out) sync In sync Out sync In sync Out sync In sync Out sync In sync Out sync Start sync Start sync Start sync Start N 11 th St San Jose CA

27 3. Error & System alarm code 3.1 System error ( Er- xxx) Code Er- Error Description How to reset 110 AD offset error When the power of controller is ON, the current offset is out of range. Reset and retry booting. If failed, repair is required RESET button 113 Spindle parameter read error Reading failure of spindle parameter Power Off On 114 Screwdriver recognition error Controller can not recognize the connected screwdriver Power Off On 115 Controller recognition error Program itself can not recognize the controller information. Power Off On 116 Out of torque range Torque setting is out of the torque capacity RESET button 118 No motor rotation error When motor rotation is not monitored RESET button 200 Parameter reading failure It failed to read parameter at all. Check the EEP-ROM damage or communication failure Power Off On 201 Parameter Checksum error The read parameter is wrong by the checksum routine Power Off On 220 Multi-sequence program error Multi-sequence program is wrong RESET button N 11 th St San Jose CA

28 3.2 Fastening error by the pattern setting ( Er- xxx) Code Er- Error Description How to reset 300 Fastening time limit Over the fastening time limit on P60 Auto reset after set time 301 Loosening time limit Over the loosening time limit on P61 Auto reset after set time 302 Model setting error Failure in Model programing. 303 Model cancel The Model process is canceled 304 Motor stall by loosening failure Motor stall by loosening failure within time limit on A272 Auto reset after set time 309 Bit socket tray Bit socket tray application error 310 Time over in screw counting Over the time limit of screw counting on A243 Auto reset after set time 311 Screw missing When the work-piece moves out of the working area without complete number of fastening, it provide alarm for set time(a277) and display the latest number. It can be clear to "0" by pressing RESET button. Auto reset after set time or RESET button 330 Min Angle error Target torque reached before the Min angle Auto reset after set time 331 Target angle setting errir Target angle setting is out of the range [ AC/TM mode] Auto reset after set time 332 Angle over Target torque reached over the Max angle Auto reset after set time 333 No torque complete Operation stops before complete cycle of torque up by releasing lever trigger Auto reset after set time N 11 th St San Jose CA

29 334 Engaging torque detection fail The engaging torque is not detected in time or angle limit Auto reset after set time 335 Converted torque error Converted torque is out of OK range Auto reset after set time 336 Over torque error torque reached to the high limit of torque Auto reset after set time 337 Sync step error1 Synchronizing time limit over before the seating point Auto reset after set time 338 Sync step error2 Synchronizing time limit over after the seating point Auto reset after set time N 11 th St San Jose CA

30 3.3 System alarm ( AL- xx) N 11 th St San Jose CA

31 N 11 th St San Jose CA